SSPC-Tester/SSPCTester.UI/Services/SafetyMonitorService.cs

using System.Diagnostics;
using System.IO;
using Microsoft.Extensions.Logging;
using Microsoft.Extensions.Options;
using SSPCTester.Devices.Config;
using SSPCTester.Devices.Interfaces;

namespace SSPCTester.UI.Services;

public sealed class SafetyMonitorService : IDisposable
{
    private readonly ISafetyDio _safetyDio;
    private readonly IPowerSupply _power;
    private readonly ILoad _load;
    private readonly ISspc _sspc;
    private readonly DeviceOptions _options;
    private readonly UiLogSink _log;
    private readonly ILogger<SafetyMonitorService> _logger;
    private readonly SemaphoreSlim _gate = new(1, 1);
    private readonly string _traceLogPath;
    private readonly object _traceLock = new();
    private Timer? _timer;
    private bool _handlingEmergency;
    private bool _softwareEmergencyActive;
    private bool _hardwareEmergencyLatched;
    private bool _disposed;
    private long _pollSequence;
    private long _pollGateBusyCount;
    private string? _lastStatusSnapshot;
    private string? _lastPollSnapshot;

    public SafetyMonitorService(
        ISafetyDio safetyDio,
        IPowerSupply power,
        ILoad load,
        ISspc sspc,
        IOptions<DeviceOptions> options,
        UiLogSink log,
        ILogger<SafetyMonitorService> logger)
    {
        _safetyDio = safetyDio;
        _power = power;
        _load = load;
        _sspc = sspc;
        _options = options.Value;
        _log = log;
        _logger = logger;

        string logDir = Path.Combine(
            Environment.GetFolderPath(Environment.SpecialFolder.LocalApplicationData),
            "SSPCTester",
            "Logs");
        Directory.CreateDirectory(logDir);
        _traceLogPath = Path.Combine(logDir, $"safety-trace-{DateTime.Now:yyyyMMdd-HHmmss}.log");
        Trace($"Safety trace started. UseMock={_options.Pci2312.UseMock}, AutoConnect={_options.Pci2312.AutoConnect}, Enabled={_options.Pci2312.Enabled}, PollIntervalMs={_options.Pci2312.PollIntervalMs}");
    }

    public bool IsEmergencyActive { get; private set; }
    public bool IsAlarmOutputOn { get; private set; }
    public string StatusText { get; private set; } = "设备故障";
    public string DetailText { get; private set; } = "设备安全监控未启动";
    public event EventHandler? StatusChanged;

    public void Start()
    {
        if (_timer is not null) return;

        var options = _options.Pci2312;
        Trace($"Start() called. Enabled={options.Enabled}, AutoConnect={options.AutoConnect}, DeviceId={options.DeviceId}, DI={options.EmergencyInputChannel}, DO={options.AlarmOutputChannel}, PollIntervalMs={options.PollIntervalMs}");
        if (!options.Enabled)
        {
            SetStatus(false, false, "设备故障", "PCI2312 安全监控未启用");
            return;
        }

        int interval = Math.Clamp(options.PollIntervalMs, 50, 10000);
        _timer = new Timer(OnTimer, null, TimeSpan.Zero, TimeSpan.FromMilliseconds(interval));
        SetStatus(false, false, "设备正常", "正在监控 PCI2312 急停输入");
        _log.Add(UiLogLevel.Info, $"安全观测日志已启用：{_traceLogPath}");
    }

    public async Task TriggerSoftwareEmergencyAsync(CancellationToken ct = default)
    {
        var sw = Stopwatch.StartNew();
        Trace("TriggerSoftwareEmergencyAsync enter.");
        await _gate.WaitAsync(ct).ConfigureAwait(false);
        try
        {
            _softwareEmergencyActive = true;
            _handlingEmergency = true;
            SetStatus(true, IsAlarmOutputOn, "软件急停已触发", "正在执行软件急停安全关断");
            _log.Add(UiLogLevel.Error, "软件触发报警急停，开始执行报警灯、电源、负载关断。");

            await EnsureSafetyDioConnectedAsync(ct).ConfigureAwait(false);
            await SetAlarmOutputAsync(true, ct).ConfigureAwait(false);
            await TryShutdownSspcAsync().ConfigureAwait(false);
            await TryShutdownPowerAsync().ConfigureAwait(false);
            await TryShutdownLoadAsync().ConfigureAwait(false);
            SetStatus(true, true, "软件急停已触发", "报警灯已接通，SSPC 通道已全部关断，电源输出和负载输入已发送关闭指令");
            Trace($"TriggerSoftwareEmergencyAsync success in {sw.ElapsedMilliseconds}ms.");
        }
        catch (Exception ex)
        {
            _softwareEmergencyActive = false;
            _handlingEmergency = false;
            _logger.LogError(ex, "Software emergency shutdown failed.");
            _log.Add(UiLogLevel.Error, $"软件急停执行异常：{ex.Message}");
            SetStatus(true, IsAlarmOutputOn, "设备故障", ex.Message);
            Trace($"TriggerSoftwareEmergencyAsync failed in {sw.ElapsedMilliseconds}ms. {ex.GetType().Name}: {ex.Message}");
            throw;
        }
        finally
        {
            _gate.Release();
        }
    }

    public async Task<SafetyResetResult> ResetAsync(CancellationToken ct = default)
    {
        await _gate.WaitAsync(ct).ConfigureAwait(false);
        try
        {
            return await ResetCoreAsync(ct).ConfigureAwait(false);
        }
        finally
        {
            _gate.Release();
        }
    }

    private async Task<SafetyResetResult> ResetCoreAsync(CancellationToken ct)
    {
        Trace("ResetCoreAsync enter.");
        var options = _options.Pci2312;
        await EnsureSafetyDioConnectedAsync(ct).ConfigureAwait(false);
        if (await IsEmergencyInputActiveAsync(options, ct).ConfigureAwait(false))
        {
            const string message = "硬件急停按钮仍处于触发状态，无法执行状态重置。请先旋转或释放设备上的急停按钮，确认急停输入复位后再重试。";
            SetStatus(true, IsAlarmOutputOn, "急停已触发", message);
            Trace("ResetCoreAsync blocked: emergency input still active.");
            return new SafetyResetResult(false, message);
        }

        await SetAlarmOutputAsync(false, ct).ConfigureAwait(false);
        _softwareEmergencyActive = false;
        _hardwareEmergencyLatched = false;
        _handlingEmergency = false;
        SetStatus(false, false, "设备正常", "急停状态已重置，报警灯已关闭，正在监控 PCI2312 输入");
        Trace("ResetCoreAsync success.");
        return new SafetyResetResult(true, "急停状态已重置。");
    }

    private void OnTimer(object? state)
    {
        if (_disposed) return;
        _ = PollAsync();
    }

    private async Task PollAsync()
    {
        if (!await _gate.WaitAsync(0).ConfigureAwait(false))
        {
            long skipped = Interlocked.Increment(ref _pollGateBusyCount);
            if (skipped % 20 == 0)
                Trace($"PollAsync skipped by gate contention. skipped={skipped}");
            return;
        }
        try
        {
            long seq = Interlocked.Increment(ref _pollSequence);
            var options = _options.Pci2312;
            if (!options.Enabled) return;

            if (options.AutoConnect && !_safetyDio.IsConnected)
            {
                Trace($"Poll#{seq}: attempting auto connect for safety DIO.");
                await _safetyDio.ConnectAsync().ConfigureAwait(false);
            }

            bool active = await IsEmergencyInputActiveAsync(options, CancellationToken.None).ConfigureAwait(false);
            string snapshot = $"poll={seq},active={active},handling={_handlingEmergency},soft={_softwareEmergencyActive},latched={_hardwareEmergencyLatched},emergency={IsEmergencyActive},alarm={IsAlarmOutputOn},dioConnected={_safetyDio.IsConnected}";
            if (!string.Equals(_lastPollSnapshot, snapshot, StringComparison.Ordinal))
            {
                _lastPollSnapshot = snapshot;
                Trace($"Poll snapshot: {snapshot}");
            }

            if (active)
            {
                _hardwareEmergencyLatched = true;
                Trace($"Poll#{seq}: branch=ACTIVE -> HandleEmergencyAsync");
                await HandleEmergencyAsync().ConfigureAwait(false);
            }
            else if (_hardwareEmergencyLatched)
            {
                Trace($"Poll#{seq}: branch=HardwareLatchedClear -> ClearHardwareEmergencyAsync");
                await ClearHardwareEmergencyAsync(options).ConfigureAwait(false);
            }
            else if (_softwareEmergencyActive)
            {
                Trace($"Poll#{seq}: branch=SoftwareActiveWaitReset");
                SetStatus(true, IsAlarmOutputOn, "软件急停已触发", "等待状态重置，电源和负载不会自动恢复");
            }
            else if (IsEmergencyActive || IsAlarmOutputOn)
            {
                Trace($"Poll#{seq}: branch=CleanupByStatus -> ClearHardwareEmergencyAsync");
                await ClearHardwareEmergencyAsync(options).ConfigureAwait(false);
            }
            else
            {
                SetStatus(false, false, "设备正常", $"DI{options.EmergencyInputChannel} 未触发");
            }
        }
        catch (Exception ex)
        {
            _logger.LogWarning(ex, "Safety monitor poll failed.");
            SetStatus(IsEmergencyActive, IsAlarmOutputOn, "设备故障", ex.Message);
            Trace($"PollAsync failed. {ex.GetType().Name}: {ex.Message}");
        }
        finally
        {
            _gate.Release();
        }
    }

    private async Task HandleEmergencyAsync()
    {
        if (_handlingEmergency)
        {
            Trace("HandleEmergencyAsync skipped because _handlingEmergency=true.");
            return;
        }

        var sw = Stopwatch.StartNew();
        _handlingEmergency = true;
        SetStatus(true, IsAlarmOutputOn, "急停已触发", "正在执行安全关断");
        _log.Add(UiLogLevel.Error, "检测到急停输入接通，开始执行报警灯、电源、负载关断。");
        Trace("HandleEmergencyAsync begin.");

        try
        {
            var step = Stopwatch.StartNew();
            await SetAlarmOutputAsync(true, CancellationToken.None).ConfigureAwait(false);
            Trace($"HandleEmergencyAsync step SetAlarmOutputAsync OK in {step.ElapsedMilliseconds}ms.");

            step.Restart();
            await TryShutdownSspcAsync().ConfigureAwait(false);
            Trace($"HandleEmergencyAsync step TryShutdownSspcAsync done in {step.ElapsedMilliseconds}ms.");

            step.Restart();
            await TryShutdownPowerAsync().ConfigureAwait(false);
            Trace($"HandleEmergencyAsync step TryShutdownPowerAsync done in {step.ElapsedMilliseconds}ms.");

            step.Restart();
            await TryShutdownLoadAsync().ConfigureAwait(false);
            Trace($"HandleEmergencyAsync step TryShutdownLoadAsync done in {step.ElapsedMilliseconds}ms.");
            SetStatus(true, true, "急停已触发", "报警灯已接通，SSPC 通道已全部关断，电源输出和负载输入已发送关闭指令");
            Trace($"HandleEmergencyAsync success in {sw.ElapsedMilliseconds}ms.");
        }
        catch (Exception ex)
        {
            _logger.LogError(ex, "Emergency shutdown failed.");
            _log.Add(UiLogLevel.Error, $"急停关断执行异常：{ex.Message}");
            SetStatus(true, IsAlarmOutputOn, "设备故障", ex.Message);
            _handlingEmergency = false;
            Trace($"HandleEmergencyAsync failed in {sw.ElapsedMilliseconds}ms. {ex.GetType().Name}: {ex.Message}");
        }
    }

    private async Task ClearHardwareEmergencyAsync(Pci2312Options options)
    {
        var sw = Stopwatch.StartNew();
        Trace("ClearHardwareEmergencyAsync begin.");
        if (IsAlarmOutputOn)
            await SetAlarmOutputAsync(false, CancellationToken.None).ConfigureAwait(false);

        _handlingEmergency = false;
        _softwareEmergencyActive = false;
        _hardwareEmergencyLatched = false;
        SetStatus(false, false, "设备正常", $"DI{options.EmergencyInputChannel} 已复位，硬件急停已解除，报警灯已关闭，设备输出不会自动恢复");
        _log.Add(UiLogLevel.Info, "硬件急停输入已复位，软件急停状态和报警灯已自动解除。");
        Trace($"ClearHardwareEmergencyAsync success in {sw.ElapsedMilliseconds}ms.");
    }

    private async Task TryShutdownSspcAsync()
    {
        try
        {
            if (!_sspc.IsConnected && _options.Sspc.AutoConnect)
            {
                Trace("TryShutdownSspcAsync: auto-connecting SSPC.");
                await _sspc.ConnectAsync().ConfigureAwait(false);
            }
            if (_sspc.IsConnected)
            {
                for (int ch = 1; ch <= _sspc.ChannelCount; ch++)
                {
                    try { await _sspc.TurnOffAsync(ch).ConfigureAwait(false); }
                    catch (Exception ex) { _logger.LogWarning(ex, "急停关断 SSPC CH{Ch} 失败。", ch); }
                }
                _log.Add(UiLogLevel.Warning, $"SSPC 全部 {_sspc.ChannelCount} 个通道已发送关断指令。");
            }
            else
            {
                _log.Add(UiLogLevel.Warning, "SSPC 未连接，跳过通道关断。");
            }
        }
        catch (Exception ex)
        {
            _logger.LogWarning(ex, "SSPC 批量关断失败。");
            _log.Add(UiLogLevel.Error, $"SSPC 通道批量关断失败：{ex.Message}");
            Trace($"TryShutdownSspcAsync failed. {ex.GetType().Name}: {ex.Message}");
        }
    }

    private async Task TryShutdownPowerAsync()
    {
        try
        {
            if (!_power.IsConnected && _options.PowerSupply.AutoConnect)
            {
                Trace("TryShutdownPowerAsync: auto-connecting power supply.");
                await _power.ConnectAsync().ConfigureAwait(false);
            }
            if (_power.IsConnected)
                await _power.OutputAsync(false).ConfigureAwait(false);
            _log.Add(UiLogLevel.Warning, "UDP5080 电源输出已发送关闭指令。");
        }
        catch (Exception ex)
        {
            _logger.LogWarning(ex, "Power shutdown failed.");
            _log.Add(UiLogLevel.Error, $"UDP5080 电源关闭失败：{ex.Message}");
            Trace($"TryShutdownPowerAsync failed. {ex.GetType().Name}: {ex.Message}");
        }
    }

    private async Task TryShutdownLoadAsync()
    {
        try
        {
            if (!_load.IsConnected && _options.Load.AutoConnect)
            {
                Trace("TryShutdownLoadAsync: auto-connecting load.");
                await _load.ConnectAsync().ConfigureAwait(false);
            }
            if (_load.IsConnected)
                await _load.InputAsync(false).ConfigureAwait(false);
            _log.Add(UiLogLevel.Warning, "IT8702P 负载输入已发送关闭指令。");
        }
        catch (Exception ex)
        {
            _logger.LogWarning(ex, "Load shutdown failed.");
            _log.Add(UiLogLevel.Error, $"IT8702P 负载关闭失败：{ex.Message}");
            Trace($"TryShutdownLoadAsync failed. {ex.GetType().Name}: {ex.Message}");
        }
    }

    private async Task<bool> IsEmergencyInputActiveAsync(Pci2312Options options, CancellationToken ct)
    {
        bool value = await _safetyDio.ReadInputAsync(options.EmergencyInputChannel, ct).ConfigureAwait(false);
        return options.EmergencyInputActiveHigh ? value : !value;
    }

    private async Task SetAlarmOutputAsync(bool on, CancellationToken ct)
    {
        var options = _options.Pci2312;
        bool outputValue = options.AlarmOutputActiveHigh ? on : !on;
        await _safetyDio.WriteOutputAsync(options.AlarmOutputChannel, outputValue, ct).ConfigureAwait(false);
        IsAlarmOutputOn = on;
    }

    private async Task EnsureSafetyDioConnectedAsync(CancellationToken ct)
    {
        var options = _options.Pci2312;
        if (!options.Enabled)
            throw new InvalidOperationException("PCI2312 安全输入输出未启用，无法控制报警灯。");

        if (!_safetyDio.IsConnected)
        {
            Trace("EnsureSafetyDioConnectedAsync: connecting safety DIO.");
            await _safetyDio.ConnectAsync(ct).ConfigureAwait(false);
        }
    }

    private void SetStatus(bool emergencyActive, bool alarmOutputOn, string statusText, string detailText)
    {
        string snapshot = $"emergency={emergencyActive},alarm={alarmOutputOn},status={statusText},detail={detailText}";
        if (!string.Equals(_lastStatusSnapshot, snapshot, StringComparison.Ordinal))
        {
            _lastStatusSnapshot = snapshot;
            Trace($"SetStatus changed: {snapshot}");
        }

        IsEmergencyActive = emergencyActive;
        IsAlarmOutputOn = alarmOutputOn;
        StatusText = statusText;
        DetailText = detailText;
        StatusChanged?.Invoke(this, EventArgs.Empty);
    }

    public void Dispose()
    {
        Trace("Dispose() called. Safety monitor disposed.");
        _disposed = true;
        _timer?.Dispose();
        _gate.Dispose();
    }

    private void Trace(string message)
    {
        string line = $"{DateTime.Now:yyyy-MM-dd HH:mm:ss.fff} [T{Environment.CurrentManagedThreadId}] {message}{Environment.NewLine}";
        try
        {
            lock (_traceLock)
            {
                File.AppendAllText(_traceLogPath, line);
            }
        }
        catch
        {
            // Temporary diagnostic trace should never break runtime behavior.
        }
    }
}

public sealed record SafetyResetResult(bool Success, string Message);